Drywall repair system and method of drywall repair

ABSTRACT

Described is a drywall repair system that includes a flexible plate defining at least one void, and an anchoring protuberance extending generally transverse from a first surface of the flexible plate. The anchoring protuberance includes a hollowed center region, a first end proximate the flexible plate and a second end opposite the first end, the second end defining an anchoring hole that extends through the second end to the hollowed center region. The flexible plate is deformable and is configured to deform in order to pass through a drywall hole and reform into a generally planar shape that spans the entirety of the drywall hole once it has passed through the drywall hole. Upon anchoring the flexible plate in place by driving a securing element driven through the flexible plate and anchoring protuberance and hole and pressing against a separate surface, the plate can be covered with a hardening repair paste. Method of repairing holes in drywall surfaces utilizing such a system are also described.

BACKGROUND

Drywall repair systems and method of repairing drywall surfaces are known. Typical repair methods of small holes in dry wall involve simply spackling over a hole in drywall and smoothing the spackling material with, e.g., a putty knife. For larger holes, typically a professional will cut and enlarge the hole in the wall into a generally rectangular shape, and cut a rectangular portion of drywall than will act as a patch and is slightly smaller than the hole in the wall. A brace behind the drywall hole is secured on either side of the hole by drilling through the wall from the front, and the rectangular drywall patch is also secured to the brace using screws. Spackle can be used to cover the gaps around the rectangular drywall material patch.

Overview

The present inventor has recognized, among other things, that a problem to be solved can include providing a drywall repair system or method of repair that is capable of patching larger holes in drywall. This can be achieved without requiring professional expertise or additional drywall material for patching, or enlargement or other reconfiguration of the hole to be patched.

The present subject matter can help provide a solution to this problem, such as by providing a drywall repair system that includes a flexible plate defining at least one void, and an anchoring protuberance extending generally transverse from a first surface of the flexible plate. The anchoring protuberance includes a hollowed center region, a first end proximate the flexible plate and a second end opposite the first end, the second end defining an anchoring hole that extends through the second end to the hollowed center region. The flexible plate is deformable and is configured to deform in order to pass through a drywall hole and reform into a generally planar shape that spans the entirety of the drywall hole once it has passed through the drywall hole. Upon anchoring the flexible plate in place by driving a securing element the flexible plate and protuberance and pressing against a separate surface, the plate can be covered with a hardening repair paste. The system does not require professional cutting tools, or additional dry wall to create repair patches.

The solution presented herein further relates to a method of repairing a hole in a drywall surface. The method includes the steps of providing a first deformable plate element; deforming the deformable plate and passing the plate through the hole; allowing the plate to return to an original generally planar shape; pulling the plate flush to a back surface of the drywall using a reduction element attached to the plate; driving a securing element through the plate and through an anchoring protuberance extending from a backside of the plate until the securing element is anchored against a surface positioned behind the drywall; and applying a hardening repair paste to the front of the plate in order to patch the hole in the drywall.

This overview is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about the present patent application.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

FIG. 1A is a top perspective view of a drywall repair system according to at least one example of the present description.

FIG. 1B is a bottom perspective view of a drywall repair system according to at least one example of the present description.

FIG. 1C is a first side view of a drywall repair system according to at least one example of the present description.

FIG. 1D is a second side view of a drywall repair system according to at least one example of the present description.

FIG. 1E is a top view of a drywall repair system according to at least one example of the present description.

FIG. 2 is a perspective view of a drywall repair system in an example with an attachable anchoring protuberance.

FIG. 3 is a front view of a drywall repair system with reduction device according to at least one example of the present description.

FIG. 4 is a side view of a drywall repair system with a securing element according to at least one example of the present description.

FIGS. 5A-5E are side views illustrating various steps in a method of repairing a drywall hole according to at least one example of the present description.

FIG. 6 is a side view of a drywall repair system according to at least one example of the present description.

DETAILED DESCRIPTION

FIGS. 1A-1E illustrate elements of a drywall repair system as contemplated in the present description. Drywall repair system 100 can include a flexible plate 102. Flexible plate, in one examples, can define at least one void 104. Drywall repair system 100 can further include an anchoring protuberance 106 that extends generally transverse from a first surface 103 of the flexible plate 102. The anchoring protuberance 106 can include a hollowed center region 136 (see FIG. 4) positioned between the wall(s) 111 of the protuberance. The anchoring protuberance can further include a first end 108 that is proximate the flexible plate 102 and a second end 110 that is opposite the first end 108. The second end 110 can define an anchoring hole 112 that extends through the second end 110 into the hollowed center region 136.

In one example, the flexible plate 102 can be deformable. In such an example, the flexible plate can be configured to deform (e.g., bend or roll) in order to pass through a drywall hole and reform into its original generally planar shape once it has passed through the drywall hole. The entirety of the flexible plate can potentially be bendable or deformable. The flexible plate 102 can be sized such that when it is in its generally planar shape, it spans the entirety of the drywall hole it is to be used to patch. The flexible plate can be made of a material that can be fairly easily cut (e.g., with a scissors or razor blade), which allows the user to cut the plate into the appropriate size for a given drywall hole. For example, in various examples the flexible plate can be made of, e.g., flexible plastics, such as memory plastics, that are capable of flexing or bending and returning to their additional shape, or materials with like characteristics. As shown in FIGS. 1A-1E, the flexible plate 102 can be a porous plate. The pores 114 of the plate 102 can aid in promoting deformability of the plate and in bonding with a hardening repair paste applied to the surface of the plate.

In some examples, protuberance 106 can be monolithically formed with the flexible plate 102. For example, protuberance 106 and flexible plate 102 may be made of the same material and, potentially, formed in a common mold (where the plate 102 is manufactured using injection molding). Alternatively, the anchoring protuberance 106 can be attachable to flexible plate 102. Where the protuberance 106 is attachable to the flexible plate, the protuberance 106 may be made of a different material than the flexible plate, and potentially a less flexible material. The protuberance can be made of any number of materials, e.g., plastics. It may be desirable to use rigid or less flexible plastics for the protuberance, such that the protuberance does not bend when force is applied to it, though flexible plastics can also be used.

One example of a system with an attachable protuberance 106 is illustrated in FIG. 2. In this example, the anchoring protuberance 106 can be attached to the flexible plate 102 by pushing the first end 110 of protuberance through the large hole 150 in flexible plate 102. On the edges of the protuberance 106 can be tabs 146 that are positioned at a longitudinal distance from a collar 140 proximate the first end 108 of protuberance 106. As anchoring protuberance 106 is pushed through attachment hole 150, tabs 146 can be aligned with slots 142 (adjacent plate hole 150) allowing the tabs 146 to pass through slots 142. The diameter of collar 140 can be greater than attachment 150 such that the protuberance cannot pass entirely through the plate. Once collar 140 is flush (or nearly flush) with plate 102, the protuberance 106 can be rotated in a clock-wise or counter-clockwise direction. The distance from tabs 146 to collar 140 can be equal to or slightly greater than the thickness of the plate, such that tabs 146 are capable of rotating across the surface of the plate. After approximately 90 degrees of rotation, tabs 146 can contact plate tabs 144 which will cease the rotation and place the protuberance 106 in a locked position. The user of the system connecting the two pieces can rotate the anchoring protuberance 106 by engaging the end slots 152 present on the first end with either their finger nails or an appropriate tool. In one example, anchoring protuberance 106 can be a generally conical shape, though other shapes (e.g., cylindrical, polyhedron, and the like) are also contemplated.

As shown in FIG. 3, in at least one example, the drywall repair system of the present description can include a reduction element 118. Reduction element 118 can be configured to be attached to the at least one void 104 in plate 102. Reduction element 118 can be configured to allow a user of the system to pull the flexible plate 102 flush to the interior of the drywall after it has been initially deformed and passed through the drywall hole. In one example, the reduction element 118 can be a string or wire (as shown in FIG. 3). In such an example, the reduction element can potentially be anchored through two voids 104 in the flexible plate 102. Further, reduction element 118 can potentially be wrapped around a user's wrist to ensure that the flexible plate is not dropped behind the wall after being deformed and pushed through the wall. In another example, the reduction element can be a “zip-tie” that is anchored to the at least one void (such that the head of the zip-tie is positioned on the opposing side of the plate from the user). In such an example, the void may be thin and rectangular rather than circular. An example of a hole intended to accommodate passage through of the tail of a zip-tie, where a zip-tie is acting as a reduction element (not shown), is provided by element 104 a.

FIG. 4 illustrates another potential element of the presently described drywall repair system. As shown, drywall repair system can further include a securing element 124 that can be inserted through a first end 108 of the anchoring protuberance 106 and through the second end 110 of the anchoring protuberance 106 and ultimately pressed against a second surface 130 that is positioned behind the drywall surface 101. The securing element 124 presses against the second surface 130 which in turn translates into force by the flexible plate 102 against the drywall 101. This ensures that the two elements are generally flush before a repair paste is applied. As shown in FIG. 4, in one example the system includes a shoulder 128 inside the anchored protuberance 106 surrounding the anchor hole 112 in the second end 110. In the event that the screw is not long enough to reach a second surface 130, head 134 of securing element will be stopped at shoulder 128. The anchor hole 112 provides a surface at which the threads 138 of securing element 124 can apply compression (ensuring the force from the screw 124 pressing against surface 130 translates into plate 102 pressing against drywall 101). In one embodiment, the securing element can be a threaded screw. In various examples, the screw may have a length of between about 2 inches and about 4 inches. In one example, the screw may be a 3 inch screw. The securing could potentially be a plastic or metal screw. The second surface may be a second drywall surface positioned behind the repaired drywall surface, a cement foundation, a wooden stud, or the like.

FIGS. 5A-5E illustrate one exemplary method of repairing a hole in drywall according to the present description. The method includes providing a first deformable plate 102, such as a porous deformable plate. Next, the deformable plate 102 is deformed and the plate 102 is passed through the hole 120, as illustrated in FIG. 5A. Subsequently, the plate 102 is allowed to return to its originally generally planar shape (see, e.g., FIG. 5B), and then, is pulled back towards the surface 122 of the drywall using a reduction element 118 that is attached to the plate 102. FIG. 5C illustrates the method at this point in the process. Next, a securing element 124, such as a threaded screw, is driven through the plate 102 and through an anchoring protuberance 106 that extends from the backside of the plate until the end of the securing element is anchored against a surface positioned behind the drywall 101. The securing element 124 can engage the anchor hole 112 of the anchoring protuberance with threads 138 to ensure that the plate is firmly anchored in place by the securing element. After the securing element has been anchored, a hardening repair paste 126 can be applied to the front of the plate 102 (and potentially pushed and applied under the edges of the plate by deforming the plate at the edges of the hole) in order to patch the hole 120 in the drywall 101.

In at least one example, the reduction element 118 is removably attached to the plate 102. For example, where reduction element 118 is a string, wire, or zip-tie, the reduction element can be cut and pulled through voids through which the reduction element is routed. The removal step can occur after the securing element has been anchored to surface 130, and may occur after or before an initial layer of hardening repair paste 126 has been applied over the plate, including portions of the plate behind the existing drywall. In one embodiment, the method can include the additional step of securing the reduction element 118 to the plate 102 via at least one void (e.g. void 104) defined by the plate 102. Further, as noted above with respect to the system, the anchoring protuberance 106 may be attachable to the plate 102. Where this is the case, the presently described method can include an additional step of attaching the anchoring protuberance to the plate. The anchoring protuberance 106 may be attached to plate 102 before or after the plate has been deformed and pushed through the wall 101 (e.g. using slots 152 to lock anchoring protuberance 106 into place).

In one embodiment, the reduction element 118 can be removed from the plate 102 after application of at least one layer of hardening repair paste 126 to the front of the plate. As with the system described above, the hardening repair paste can, for example, be a spackle or plaster of paris.

In some embodiments, a surface 130 may not be present behind the wall 101 to be repaired. In such a case, the flexible plate construction 102 described herein can be used in conjunction with a brace plate 200 that is applied to the front of the wall 101. The brace plate 200 can be a generally elongate but thin plate that is rigid. In some cases the plate can be metal, and in others the plate can be plastic, though other rigid materials are also contemplated. After the reduction element has been used to pull the plate 102 flush with wall 101, the securing element 124 can be driven through a hole 202 in brace 200, the securing element can be driven until the end of the securing element engages the anchoring hole 112 of the protuberance and further until the head 134 of securing element is tightened against the surface of brace 200. This will ensure that at least a portion of brace 200 (and flexible plate 102) are held tight against the wall. A first layer of repair paste can be applied to the front of the flexible plate 102, except for the portions of the plate obstructed by the brace 200, and allowed to cure. At this point the brace can be removed, and the remainder of the surface can be covered with repair paste. Additionally or alternatively, the brace 200 may have a partially hollowed out region 204 beneath that can allow for repair paste to be applied beneath it while in place.

VARIOUS NOTES & EXAMPLES

Example 1 can include a drywall repair system, such as can include a flexible plate defining at least one void and an anchoring protuberance extending generally transverse from a first surface of the flexible plate, the anchoring protuberance comprising a hollowed center region, a first end proximate the flexible plate and a second end opposite the first end, the second end defining an anchoring hole that extends through the second end to the hollowed center region. The flexible plate can be deformable and be configured to deform in order to pass through a drywall hole and reform into a generally planar shape that spans the entirety of the drywall hole once it has passed through the drywall hole.

Example 2 can include, or can optionally be combined with the subject matter of Example 1, to optionally include that the protuberance is monolithically formed with the flexible plate.

Example 3 can include, or can optionally be combined with the subject matter of Example 1 to optionally include that the anchoring protuberance is attachable to the flexible plate.

Example 4 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1 or 3 to optionally include that the anchoring protuberance is attached to the flexible plate by sliding tabs on the anchoring protuberance through slots in the flexible plate, positioning a collared surface flush against the back surface of the flexible plate and rotating the anchoring protuberance until it reaches a locked position.

Example 5 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-4 to optionally include that the anchoring protuberance is a generally conical shape.

Example 6 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-5 to optionally include that the flexible plate is porous.

Example 7 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-6 to optionally include a reduction element configured to be attached to the at least one void, the reduction element configured to allow a user to pull the flexible plate flush to the interior of the drywall after it has passed through the hole.

Example 8 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-8 to optionally include a reduction element comprising a string or wire and anchored through two voids in the flexible plate.

Example 9 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-8 to optionally include a reduction element comprising a zip-tie anchored in the at least one void.

Example 10 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-9 to optionally include a securing element configured to be inserted through the first end and second of the anchoring protuberance and contact a second surface positioned behind the drywall surface.

Example 11 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-10 to optionally include an anchor hole in the second end, the anchor hole providing an internal surface upon which the threads of a securing element can apply compression.

Example 12 can include a method, such as can include providing a first deformable plate; deforming the deformable plate and passing the plate through the hole; allowing the plate to return to an original generally planar shape; pulling the plate flush to a back surface of the drywall using a reduction element attached to the plate; driving a securing element through the plate and through an anchoring protuberance extending from a backside of the plate until the securing element is anchored against a surface positioned behind the drywall; and applying a hardening repair paste to the front of the plate in order to patch the hole in the drywall.

Example 13 can include, or can optionally be combined with the subject matter of Example 12, to optionally include that the reduction element is removably attached to the plate.

Example 14 can include, or can optionally be combined with the subject matter of one or any combination of Examples 12 or 13 to optionally include that the reduction element is removed from the plate after application of at least one layer of hardening repair paste to the front of the plate.

Example 15 can include, or can optionally be combined with the subject matter of one or any combination of Examples 12-14 to optionally include the hardening repair paste comprises spackle or plaster of paris.

Example 16 can include, or can optionally be combined with the subject matter of one or any combination of Examples 12-15 to optionally include the securing element is anchored to an anchor hole on a side of the anchoring protuberance distal from the plate element.

Example 17 can include, or can optionally be combined with the subject matter of one or any combination of Examples 16 to optionally include the securing element comprises a threaded screw, and wherein the threaded screw engages the anchor hole of the anchoring protuberance.

Example 18 can include, or can optionally be combined with the subject matter of one or any combination of Examples 12-17 to optionally include attaching the anchoring protuberance to the plate.

Example 19 can include, or can optionally be combined with the subject matter of one or any combination of Examples 12-18 to optionally include securing the reduction element to the plate via at least one void defined by the plate.

Example 20 can include, or can optionally be combined with the subject matter of one or any combination of Examples 12-19 to optionally include that the plate is porous.

Each of these non-limiting examples can stand on its own, or can be combined in various permutations or combinations with one or more of the other examples.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventor also contemplates examples in which only those elements shown or described are provided. Moreover, the present inventor also contemplates examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

1. A drywall repair system, comprising: a flexible plate defining at least one void, wherein the entirety of the flexible plate includes a deformable material, the flexible plate configured for bending into a plurality of shapes based on the deformable material; and an anchoring protuberance extending generally transverse from a first surface of the flexible plate, the anchoring protuberance comprising a hollowed center region, a first end proximate the flexible plate and a second end opposite the first end, the second end defining an anchoring hole that extends through the second end to the hollowed center region; wherein the flexible plate is configured to deform in order to pass through a drywall hole and reform into a generally planar shape that spans the drywall hole once it has passed through the drywall hole.
 2. The drywall repair system of claim 1, wherein the flexible plate is hingeless.
 3. The drywall repair system of claim 1, wherein the anchoring protuberance is attachable to the flexible plate.
 4. The drywall repair system of claim 3, wherein the anchoring protuberance is attached to the flexible plate by sliding tabs on the anchoring protuberance through slots in the flexible plate, positioning a collared surface flush against the back surface of the flexible plate and rotating the anchoring protuberance until it reaches a locked position.
 5. The drywall repair system of claim 1, wherein the flexible plate includes a memory material, wherein the memory material is deformable to an additional shape and reformable to an original shape.
 6. The drywall repair system of claim 1, wherein the flexible plate is porous.
 7. The drywall repair system of claim 1, further comprising a reduction element configured to be attached to the at least one void, the reduction element configured to allow a user to pull the flexible plate flush to the interior of the drywall after it has passed through the hole.
 8. The drywall repair system of claim 7, wherein the reduction element comprises a string or wire and is anchored to the flexible plate.
 9. The drywall repair system of claim 7, wherein the reduction element comprises a zip-tie anchored in the at least one void.
 10. The drywall repair system of claim 1, further comprising a securing element configured to be inserted through the first and second end of the anchoring protuberance and contact a second surface positioned behind the drywall surface.
 11. The drywall repair system of claim 10, further comprising an anchor hole in the second end having an internal anchoring surface, the securing element is configured to threadably engage the internal anchoring surface to apply compression.
 12. A method of repairing a hole in a drywall surface, comprising: providing a first flexible plate, wherein the entirety of the flexible plate includes a deformable material, the flexible plate configured for bending into a plurality of shapes based on the deformable material; deforming the flexible plate and passing the plate through the hole; allowing the plate to return to an original generally planar shape; pulling the plate flush to a back surface of the drywall using a reduction element attached to the plate; driving a securing element through the plate and through an anchoring protuberance extending from a backside of the plate until the securing element is anchored against a surface positioned behind the drywall; and applying a hardening repair paste to the front of the plate in order to patch the hole in the drywall.
 13. The method of claim 12, wherein the reduction element is removably attached to the plate.
 14. The method of claim 13, wherein the reduction element is removed from the plate after application of at least one layer of hardening repair paste to the front of the plate.
 15. The method of claim 14, wherein the hardening repair paste comprises spackle or plaster of paris.
 16. The method of claim 12, wherein the securing element is anchored to an anchor hole on a side of the anchoring protuberance distal from the plate element.
 17. The method of claim 16, wherein the securing element comprises a threaded screw, and wherein the threaded screw engages the anchor hole of the anchoring protuberance.
 18. The method of claim 12, further comprising attaching the anchoring protuberance to the plate.
 19. The method of claim 12, further comprising securing the reduction element to the plate via at least one void defined by the plate.
 20. The method of claim 12, wherein the plate is porous. 